KTM Freeride E-XC 2019 Manual

SETUP INSTRUCTIONS 2019
Freeride E‑XC
Art. no. 3213880en

INTRODUCTION
*3213880en*
3213880en
01/2019
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic with the corre-
sponding HV training.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2019 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
Freeride E‑XC EU (F3001S1)

1 MEANS OF REPRESENTATION
2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies work requiring expert knowledge and technical understanding. In the interest of your
own safety, only have these jobs performed by correspondingly trained KTM technical person-
nel.
All work identified by this symbol requires a level 1 qualification for high-voltage systems. Only
this qualification authorizes you to perform non-electro-technical work on a vehicle or on units
with a high-voltage system.
All work identified by this symbol requires a level 2 qualification for high-voltage systems.
Only this qualification authorizes you to de-energize the electrical system and perform
electro-technical work in a de-energized state.
All work identified by this symbol requires a level 3 qualification for high-voltage systems. Only
this qualification authorizes you to perform electro-technical work under voltage.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.

MEANS OF REPRESENTATION 1
3
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

2 SAFETY ADVICE
4
2.1 Work rules
The KTM PowerPack does not contain any parts that require maintenance. Do not open the KTM PowerPack
under any circumstances.
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. For example: gear segment (70029032000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock
washers) must be replaced by new parts.
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. The manufacturer instructions for use
must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.2 Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
2.3 Degrees of risk and symbols
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Fuel, auxiliary substances
Use the operating and auxiliary substances (such as oils and lubricants) specified in the Owner's Manual.

SAFETY ADVICE 2
5
2.5 Fire hazard
Warning
Fire hazard Damaged rechargeable lithium-ion batteries (KTM PowerPacks) present a fire hazard.
Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause
the battery to self-ignite.
–Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat-
tery (KTM PowerPack) has occurred.
There is no particular fire hazard for this vehicle when the rechargeable lithium-ion battery (KTM PowerPack) is
intact.
However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a
rechargeable lithium-ion battery is on fire.

3 SETUP
6
3.1 Transport mode
H02712-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
3.2 Diagnostic connection
F01879-10
Diagnostic connection 1is located under the front rider's seat.
Info
The charging socket is also the diagnostic connection.
3.3 Unpacking and setting up the vehicle
E00851-10
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup,
leave the protective film on the vehicle until you have
finished.
–Remove and unpack the separate enclosure and components.
Check that the scope of supply is complete using the enclosed
packing list.
Info
The procedure in the event of missing components is
described in the customer service manual.
–To be in compliance with the homologation of the vehicle,
mount all of the parts in the separate enclosure when assem-
bling the vehicle.
Info
It is not necessary to mount all of the parts in the sepa-
rate enclosure for the vehicle to operate correctly. How-
ever, homologation will not apply if not all parts from
the separate enclosure are mounted.
–Remove the KTM PowerPack. ( p. 29)

SETUP 3
7
F01844-10
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest
bracket.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the customer service manual.
F01849-10
–Remove the spare key and KEYCODECARD keep in a safe place
for the handover.
–Loosen rubber strap 1and tilt the headlight mask forwards.
E00971-10
–Disconnect the plug-in connector 2of the headlight and the
plug-in connector 3of the ignition lock.
–Lay down the headlight mask carefully to the side and protect
from damage.
F01234-01
–Make sure that the reflectors are glued on to the left and right
fork leg.
» If there are no reflectors stuck on:
–Stick on the reflector.
Info
The reflectors must not be covered by trim
parts.

3 SETUP
8
F01852-10
–Remove screws 4. Take off handlebar supports.
–Place handlebar supports in required position. Mount and
tighten screws 4.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
The handlebar supports can be mounted in four differ-
ent positions.
Position the left and right handlebar supports evenly.
F01842-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
The handlebar clamps and screws are in the accessory
pack.
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the installed gap widths equal when tightening.
F01853-10
–Secure the handlebar cushion with two cable ties.

SETUP 3
9
F01846-01
–Position the controls on the right half of the handlebar.
–Route the cable without tension and secure with cable ties and
cable holders.
402390-01
–Mount turn signal switch and route cable to the front.
F01848-01
–Position the controls on the left half of the handlebar.
–Route the cable without tension and secure with cable ties and
cable holders.

3 SETUP
10
H01060-01
–Mount the mirror clamps on both sides.
F01859-01
–Mount and tighten the rear mirror on both sides.
E00962-01
–Preassemble the hand guards on the left and right.

SETUP 3
11
F01860-10
–Mount the left hand guard.
–Mount the right hand guard.
F01845-10
–Position the front fender. Mount and tighten screws 5.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screws 6.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
F01847-01
–Release the axle clamp screws and remove the wheel spindle.
–Install the front wheel. ( p. 21)

3 SETUP
12
F01854-10
–Position the turn signal on the headlight mask on both sides,
mount nuts with washers and tighten.
–Mount turn signal relay 7with lock washer 8and
screw 9.
E00967-01
–Position the turn signal on both sides on the license plate
holder, mount nuts with washers and tighten.
F01855-10
–Position the license plate lamp on the license plate holder
extension, and mount and tighten screw bk.
F01856-10
–Mount reflector bl on the license plate holder with the spring
washer.

SETUP 3
13
F01857-10
–Position turn signal indicator lamp bm in the combination
instrument rack.
F01858-10
–Join plug-in connector bn of the turn signal cable.
–Make sure that the bulb is located in socket bo.
» If there is no bulb in the socket:
–Insert the bulb included in the accessory pack in
socket bo.
Indicator lamps (W2.3W / socket W2x4.6d)
–Position the cable with socket and bulb in turn signal control
lamp bm.
–Install the headlight mask with the headlight. ( p. 33)
–Check the headlight setting. ( p. 33)
F01851-10
–Fold the seat up. ( p. 22)
–Remove 12-V battery bp.
–Charge the 12-V battery. ( p. 27)
F01861-10
–Remove screws bq and hang the battery compartment to the
side.
F01877-10
–Remove screws br.
–Remove screws bs.
–Lower the license plate holder and hang the tail light to the
side.
Info
Pay attention to the cable of the tail light.

3 SETUP
14
F01868-10
–Drill a hole at marking Ato the size of the marking.
F01869-10
–Route the turn signal cable harness through the frame from
the front to the rear paying attention to the plugs as you do so.
F01865-10
–Join the turn signal cable harness plug-in connector to the
main wiring harness plug-in connector.
–Position the battery compartment and mount and tighten
screws bq.
Info
The wiring harness runs under the battery compart-
ment.
–Lock the seat. ( p. 22)
F01878-10
–Route the turn signal cable on the left side on the license
plate holder and feed the turn signal cable through the hole.
–Route the cable of the tail light on the right side on the license
plate holder.
F01876-10
–Position the license plate holder on the rear.
Info
Ensure that the cable is routed correctly.
–Mount and tighten screws br.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Position the tail light on the license plate holder.
–Mount and tighten screws bs.

SETUP 3
15
F01866-01
–Route turn signal cable to the rear through the license plate
holder extension.
F01867-10
–Make sure that the bulb is located in the socket.
» If there is no bulb in the socket:
–Insert the bulb included in the accessory pack in the
socket.
License plate lamp (W5W/socket W2.1x9.5d)
–Insert the cable with the socket and bulb in the license plate
lamp.
–Connect the plug-in connector of the left turn signal which is
marked red.
–Connect the plug-in connector of the right turn signal which is
marked green.
–Position the license plate holder extension on the license plate
bracket.
Info
Make sure the cables and plug-in connections are posi-
tioned correctly.
–Mount and tighten screws bt.
M00695-01
–Mount the footrests with the springs and pins. Secure the pins
using the washers and cotter pins.
Footrest spring plier (58429083000)
F01872-10
–Remove screw ck.
Info
The screw can be reached through a drill hole in the
motor cover.

3 SETUP
16
F01871-10
–Remove clamp cl.
–Remove the cable ties.
–Pull the wiring harness and brake line aside slightly.
F01873-10
Note
Material damage The ferrite core has a one-way lock.
If the locked ferrite core is reopened, the lock is destroyed.
–Before installing the ferrite core, ensure it is properly posi-
tioned.
–Position ferrite core cm around the lighting wiring harness and
close it.
The ferrite core is fully closed and locked.
F01874-10
–Position the wiring harnesses, ferrite core, and brake line on
the motor.
–Position clamp cl.
F01872-10
–Mount and tighten screw ck.
Guideline
Remaining screws for
motor
M6 10 Nm (7.4 lbf ft)
The clamp is fully closed but the cable is not pinched.
F01875-10
–Mount the cable ties.
–Carry out the unlocking procedure for the KTM PowerPack.
( p. 22)
–Charge the KTM PowerPack. ( p. 25)
–Set the combination instrument. ( p. 34)
–Set the kilometers or miles. ( p. 35)
–Set the clock. ( p. 36)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).

SETUP 3
17
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Remove remaining protective film.
–Attach the stickers included in the scope of supply (optional).
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

4 WORK
18
4.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
Preparatory work
–Deactivate the vehicle. ( p. 19)
–Fold the seat up. ( p. 22)
–Remove the KTM PowerPack. ( p. 29)
(Option: HV 2 technical personnel)
–Ascertain that the KTM PowerPack is at zero potential.
( p. 36)
–Ascertain that the discharge plug is de-energized.
( p. 37)
–Mount the protection cap. ( p. 19)
401942-01
Main work
–Use the motor guard underneath the motor to raise the vehicle.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
4.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401943-10
Main work
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with the rubber strap.
Finishing work
–Install the KTM PowerPack. ( p. 30)
(Option: HV 2 technical personnel)
–Perform an equipotential bonding check (KTM PowerPack
installed). ( p. 37)
–Lock the seat. ( p. 22)